Natural fiber-based insulated panel and temperature controlled shipping system

ABSTRACT

A natural fiber-based insulating panel system to facilitate shipping. One or more natural fiber-based panels are inserted into the interior of a shipping container to encapsulate the payload, or on the exterior of the shipping container to encapsulate the shipping container and payload. A film or membrane may encapsulate one or more of the insulating panels. Micro perforations may be present in the membrane to facilitate the capture of moisture from the interior.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. Pat. Application No.17/168,131, filed Feb. 4, 2021 and entitled “Natural Fiber-BasedInsulated Panel And Temperature Controlled Shipping System.”

BACKGROUND/SUMMARY BACKGROUND Field of the Invention

The present invention relates generally to a natural fiber-basedinsulated panel and temperature controlled shipping system, and moreparticularly, to panels that can be constructed from a natural fibermaterial such as hemp, and that maintain a rigidity level that allowsthem to be inserted into shipping containers and or be formed intoshipping containers.

Background

Consumers and industry players alike are demandingtemperature-controlled shipping systems that are more and moreenvironmentally friendly. This is especially true in view of theCovid-19 pandemic during which the world sheltered in place and began toorder all life’s necessities on-line. This live change has resulted inan increase in the demand for temperature-controlled shipping systems,which, in turn has resulted in greatly impacting the amount of refusegenerated due to such demand. Currently, there are a number of solutionsfor temperature-controlled shipping systems on the market. Some of thesesolutions attempt to use expanded polystyrene (EPS) or polyurethaneinsulation as insulating panels, but these solutions fail to meet theneeds of the industry because of the hugely negative environmentalimpact that petroleum-based insulated panels and containers have bothduring their manufacture and in their post-use disposal. The manufactureof these petroleum-based insulating panels requires high amounts ofenergy and chemicals and results in pollution from the chemicalprocessing. These petroleum-based insulating panels are bulky,essentially non-recyclable, and continue to clog our landfills andwaterways. Other solutions attempt to replace petroleum-based insulationwith insulating panels made from cotton fibers or paper. But thesesolutions are similarly unable to meet the needs of the industry for anenvironmentally-sound shipping systems because of the high levels ofenergy and chemicals used in the manufacture of the insulating fibersand the resulting pollution from the chemical processing. Still, othersolutions seek to form insulating panels out of bio-based starches, butthese solutions also fail to meet industry needs because of the energyand chemicals used in their manufacture, and the poorer thermalperformance provided by the bio-based starch insulating panels.

Thus, there is a need in the art for a solution that provides sufficientinsulation for items being shipped or stored, that is versatile, thatprovides a level of protection against shock or vibration and that isenvironmentally sound.

BRIEF SUMMARY

Embodiments of the present invention include a system and method forcontrolling the temperature of packaged goods during transportation (orstorage). In various embodiments, the system may include a uniquecombination of insulating panels and optionally a shipping container.The system utilizes insulated panels formed from natural fibers (such ashemp fibers and/or other natural fibers), placed within the interior oron the exterior of a shipping container or payload, to form a thermalbarrier around the goods being shipped, thereby helping to keep thegoods at a more optimum and consistent temperature during transportationor storage. In an exemplary embodiment, the components may include: hempand other plant-based fibers that are formed into insulating mats orpanels, such as through mechanical processing, however, in someembodiments, chemical processing may also be performed in addition to orin lieu of the mechanical processing. Exemplary embodiments of theinsulating mats or panels of natural fiber or hemp-based insulation mayvary in thickness depending on the particular application. In variousembodiments, the thickness may range from less than 0.5 inches to 2 ormore inches. In a particular embodiment, the thickness of the insulatingpanel may be approximately 1.5 inches in thickness. Further, theinsulation panels may be cut to a size and shape that can be insertedinto or wrapped around a box, payload or other shipping container so asto cover each of the sides of the container or payload and thus,encapsulate the payload or container. In some embodiments, theindividual insulated panels can be wholly encased or partially coveredby a plastic, bio-plastic, paper or other film to enhance the overallperformance of each insulated panel. The various embodiments can be usedto form a thermal barrier between the space inside the shippingcontainer and the outside environment, thus creating an environmentallyfriendly, temperature controlled shipping system that is recyclable andcompostable after use. Furthermore, it should be noted the manufactureof the hemp and other natural fiber insulated panels described in thisinvention use far less energy and chemicals to produce than conventionalexpanded polystyrene (or extruded polystyrene-based, paper-based orcotton-fiber-based insulation. Insulated shipping systems formed usingthe insulated panels described herein thus have a substantially lowerimpact on the environment than other existing thermally-controlledshipping solutions.

In an exemplary embodiment of an insulated shipper (including a shippingcontainer and one or more insulation panels) the shipper is an essentialpart of a temperature-controlled packaging system used to shiptemperature-sensitive products such as food items, organs, drugs andother perishable products. Traditionally, petroleum-based insulationmaterials, such as expanded polystyrene (EPS) foams and polyurethanefoams have been used as the main insulating material fortemperature-controlled shippers. These existing conventional shippersare not environmentally-friendly. They are petroleum-based, contributeto pollution during their manufacture, and continue to be anenvironmental problem after their use. Most conventional shippers arenot reused or reusable, are not biodegradable and result in clogginglandfills. In the recent years, a growing number of bio-based insulatedshippers offering some level of compostability and/or recyclability havecome on the market. The insulation used in these new shippers is mostoften based on paper or cotton fiber. Although these more recentofferings are somewhat more environmentally friendly thanpetroleum-based insulation, the harvesting and processing of the rawmaterials used to manufacture these non-petroleum-based insulationproducts present an ecological and carbon footprint that is not optimum.Large amounts of energy, chemicals and water are required to processcotton and wood fiber (paper) into usable insulation. The chemicals usedin the processing of these fibers lead to post-process waste streamsthat pollute the environment. Additionally, the growth and processing ofcotton is one of the most water-intensive, chemical-intensive andenergy-intensive of all natural fibers. Accordingly, there is a need forbio-based insulation that: is rapidly-renewable; sequesters more CO2 perunit of usable fiber; uses less pesticides, fertilizers and water duringgrowth; and uses less energy and chemicals during processing of theplant fibers into usable insulation; and generates less chemicalpollution. The disclosed device and associated method advantageouslyfill these needs and other considerations. Various embodiments of thepresent invention address the aforementioned deficiencies by providing arecyclable and compostable, natural fiber or hemp-based insulation andtemperature-controlled packaging system that has insulating andtemperature control properties on par or better than existing solutions,while at the same time: sequestering more CO2 per pound of insulationfiber; using less pesticide, fertilizer and water during growth; usingless energy, chemicals and water during manufacture; and creating lesschemical pollution during processing of the plant fibers into usableinsulation.

The present disclosure thus presents embodiments of atemperature-controlled shipping system, which may include the followingcomponents: insulating mats or panels that are flexible yetdimensionally-stable, made primarily of natural fibers or hemp fibers ora combination of hemp fibers and other mechanically-processed naturalfibers, and a box or other shipping container into which or around whichthe insulating panels are placed. These components are arranged in sucha manner that the insulating panels form a continuous or nearlycontinuous layer inside or around the shipping container or payload,thus creating a barrier to heat transfer between the inside of theshipping container and the outside environment. The contents inside theshipping container are thus kept at a more optimum and consistenttemperature during transportation or storage.

The hemp or other natural fiber insulation is manufactured using littleor no chemicals in the processing of the harvested plant biomass intoinsulating fibers. The harvested and retted natural fibers, such as hempstraws, are mechanically decorticated to separate the desired type ofnatural or hemp fibers. In some embodiments, the fibers are furtherprocessed with a binding agent being mixed with the natural or hempfibers and heated to a specific temperature whereby the binding agentmelts and holds the mixture together. The resulting mat is compressed tothe desired material density and maintains both its flexibility anddimensional stability after cooling. It should be appreciated that othermanufacturing techniques are also anticipated. As needed, the mat isthen cut into panels to fit a specific shipping container or payload.The flexibility of the insulating panels allows them to be folded sothat the panels can adapt to the interior or exterior of the targetshipping container. Further, the panels can be scored or sculpted tofurther facilitate the ability to be folded. The mats and panels soformed are reusable, recyclable and compostable.

The various embodiments may also include one or more of the following:To limit convective movement of air through the insulating panels andimprove their thermal performance, the insulating panels may be whollyor partially wrapped in a film, coating, cover or membrane (hereincollectively referred to as film) such as low-density polyethylene(LDPE), kraft paper, bio-plastics or other materials. The film may beperforated or include a plurality of apertures to allow the flow ofmoisture from the payload inside the shipping container into natural orhemp fibers, thus enabling the moisture-absorbing natural or hemp fibersto regulate the moisture content in the packaging system. Theperforations will also eliminate trapped air pockets in the insulatingpanels that could interfere with the folding and assembly of theinsulating panels into or around the shipping container.

The material used to bind the insulating fibers may be 100% polyester ora mixture of polyester and other synthetic fibers. Alternatively, inorder to improve end-of-life recycling and composting options, bio-basedbinders such as Polylactic acid (PLA) may be used. In an exemplaryembodiment, the quantity of hemp fibers is substantially greater thanthe quantity of the binder by volume. As a non-limiting example, thecontent of binding fibers in the insulated panel may be less than 10%,such as 8% polyester and 92% natural or hemp fibers. In otherembodiments, the insulated panels may include more than 10% of thebinding fibers by volume or less than 10% of the binding fibers byvolume. Further, in an exemplary embodiment, the insulated panels mayinclude 90% natural or hemp fibers but, in other embodiments theinsulated panels may include more or less than 90% natural or hempfibers. In some embodiments, the ratio of natural fibers or hemp fibersto binder may be uniform throughout the insulated panels. However, inother embodiments, the ratio of natural or hemp fibers to the binder mayvary throughout the insulated panel. For instance, the ratio may bemodified to improve the rigidity along the perimeter of an insulatedpanel, to increase the thermal characteristics of a certain area of theinsulated panel, to increase the flexibility of a portion of theinsulated panel (i.e., along a fold line), etc.

For instance, in another embodiment, insulated panels may be fabricatedwith 40% or more natural or hemp fibers. In yet another embodiment,insulated panels consist of more than 40% natural or hemp fibers andapproximately 10% polyester or binder. In yet another embodiment, theinsulated panels may consist of 40% or more natural or hemp fibers andapproximately 10% or less polyester or binder. In yet even otherembodiments, the insulated panels may consist of approximately 46% hemp,approximately 46% post-industrial virgin paper fiber and 8% polyester.Such embodiments advantageously can be fabricated at a lower cost,produce less dust in the manufacturing process, and provide an improvedthermal performance. It should be appreciated that other variations infabrication of the insulated panels may also be implemented in thevarious embodiments.

In the various embodiments described herein, the insulated panels may beconstructed of natural fibers, hemp fibers or include a mix of hempfibers with other natural fibers and/or machine created fibers. Whilevarious embodiments may be described as using hemp fibers, it should beappreciated that this is only provided as a non-limiting example andother natural fibers may also be suitable for such embodiments. However,with the increase in the interest of growing hemp, the variousembodiments are described as utilizing hemp fibers. And while othernatural fibers may be substituted, it should be appreciated in the useof hemp fibers or combinations of hemp with other natural fibers may inand of itself comprise a patentable element in various embodiments.

To form an insulated shipping system, the natural fiber insulatingpanels can be installed on the inside or outside of the shippingcontainer. The shipping container may be comprised of a single containerof almost any shape such, as a cardboard or plastic box, tube, can ordrum. The shipping container could also be comprised of multipleindividual shipping containers assembled into a whole, such as a palletof several boxes or containers, which is then wrapped with one or moreinsulating panels.

The insulating panels, which are placed on the inside or outside of abox shaped shipping container, can be configured in numerous ways,including but not limited to:

A 2-panel system whereby each insulating panel covers three sides of theshipping container,

A 3-panel system whereby one insulating panel covers the bottom surfaceof the shipping container, one insulating panel covers the top, and onelong insulating panel covers the 4 vertical sides of the shippingcontainer,

A 6-panel system whereby there is an independent insulating panel foreach side of the box.

A stacked panel system whereby 2 or more insulating panels are stackedon top of each other inside the shipping container. One or more of thestacked panels may have one or more cutouts to hold products such asbottles, vials or other packages. Additional cutouts could be made tohold devices that would further enhance the temperature stability of theoverall system such as: gel-packs for cooling, dry-ice for cooling, andphase change materials for hot or cold temperature control.

A wrap-around system whereby insulating panels are wrapped on theoutside of the shipping container or assembly of shipping containers.

It should be appreciated that other shaped containers and/or payloadscan be equally addressed in various embodiments. As a non-limitingexample, a two-piece spherical insulating panel system can be utilizedfor round objects. Other shapes and sizes are also anticipated by thevarious embodiments of the invention in that the panels can be sized andshaped for any application. It should also be appreciated that while thevarious embodiments refer to insulating panels, the panels are notnecessarily always flat panels. In some embodiments the panels may bethree-dimensionally shaped and include a variety of contours andsurfaces.

A material, such as an adhesive or a device such as VELCRO or other hookand loop material may be used along the edges where the insulatingpanels meet so as to minimize any gaps between the assembled insulatingpanels. Further, in some embodiments the edges of the insulating panelsmay be configured to be interlocked, such as with a series of teeth andgaps that allow the panels to be secured together and may improve theoverall thermal retention of the enclosure.

The various embodiments are unique when compared with other knowndevices and techniques because they provide a temperature controlledshipping system consisting of natural or hemp-based fiber insulatingpanels (comprised of hemp and possibly other natural fibers plus abinding agent) and a shipping container: (1) that is moreenvironmentally friendly than other shipping systems since during themanufacture of the insulating fibers and the insulating panels: fewerchemicals, less water, and less energy is used; less chemical pollutionis created; and more CO2 is sequestered; (2) where the natural fiber orhemp-based insulating panels are reusable, compostable and/orrecyclable; (3) where the natural fiber or hemp-based insulating panelsare able to absorb moisture; (4) where the film or membrane that mayencapsulate the natural fiber or hemp-based insulating panels, eitherwholly or in part, is perforated or includes apertures to allow moistureto pass from the interior of the shipping container into the hemp-basedinsulation, thus helping to prevent the buildup of potentially harmfulmoisture inside the shipping container; (5) where the natural fiber orhemp-based insulating panels are able to absorb some mechanical shockduring transportation, thus helping to prevent damage to the goods inthe shipping container; (6) where the shape-stable yet flexible natureof the natural fiber or hemp-based insulating panels allows for a highdegree of flexibility in the specific configuration of the insulatingpanels inside or around the shipping container.

Similarly, the various methods presented here are unique when comparedwith other known processes and solutions in that: (1) the methods ofmechanically processing the natural fiber or hemp plant fibers intofibers usable for insulating panels uses fewer chemicals, uses lesswater, uses less energy, creates less chemical pollution and sequestersmore CO2 than other types of bio-based fibers such as cotton and paper;(2) the specific formation of the natural fiber or hemp fibers and thecombining of those fibers with a binding agent is done in a way wherebythe resulting un-encapsulated insulating panel: has excellent insulatingproperties, is shape stable yet flexible, is able to absorb moisture,and is reusable, recyclable and compostable; (3) the combining of theraw natural fiber or hemp insulating panels with an encapsulating filmis done in a way whereby the resulting encapsulated insulating panel isshape stable yet flexible, is able to absorb moisture, and is recyclableand compostable.

The disclosed embodiments are unique in that they are structurallydifferent from other known devices or solutions. More specifically, theembodiments are unique due to: (1) the use of natural fibers or hempfibers to create insulating panels for use in an insulated, temperaturecontrolled shipping system; (2) the encapsulation of those insulatingnatural fiber or hemp panels, either in whole or in part, with a filmthat reduces the amount of particulate matter that sheds from thenatural fiber or hemp insulating panels during use; (3) theencapsulation of those insulating natural fiber or hemp panels, eitherin whole or in part, with a breathable film; (4) the use of anencapsulating film that is recyclable and/or compostable; (5) the use ofinsulating natural fiber or hemp panels that incorporate a type ofnatural fiber or hemp fiber and an amount and type of binder agent thatallows the resulting insulating panel to be compostable and/orrecyclable; (6) the use of insulating natural fiber or hemp panels thatare able to absorb moisture; (7) the use of insulating natural fiber orhemp panels that are able to bend and flex at least 90 degrees or more,while not breaking and still maintaining their insulating properties;(8) the use of insulating natural fiber or hemp panels that areshape-stable and have the ability to maintain their shape and overallstructure when portions of the insulating panel are cut out (forexample, a circular cut-out in the center of an insulating panel) thuscreating an interior cavity in which a product (for example, a bottle oftemperature sensitive liquid) can be both thermally and mechanicallyprotected during transportation; (9) the fact that the shipping systemconsists of a unique combination of a container (for example, a box) andnatural fiber or hemp-based insulating panels (encapsulated, partiallyencapsulated or un-encapsulated) placed in the inside or on the outsideof the shipping container, that reduces heat transfer between theinterior of the container and the external environment.

Furthermore, the processes associated with the aforementionedembodiments are likewise unique. More specifically, the disclosedprocesses are unique due to the fact that: (1) the insulating naturalfiber or hemp panels are formulated using a type of natural fiber orhemp fiber and an amount and type of binder agent that allows theresulting insulating panel to be compostable and/or recyclable; (2) theinsulating natural fiber or hemp panels are formulated in a way wherebyare able to absorb moisture; (3) the insulating natural fiber or hemppanels are formulated in a way whereby the natural fiber or hemp panelsthat are able to bend and flex at least 90 degrees or more, while notbreaking and still maintaining their insulating properties; (4) theinsulating natural fiber or hemp panels are formulated in a way wherebythey are shape-stable and have the ability to maintain their shape andoverall structure when portions of the insulating panel are cut out (forexample, a circular cut-out in the center of an insulating panel);

This disclosure now provides a more detailed and specific descriptionthat will refer to the accompanying drawings. The drawings and specificdescriptions of the drawings, as well as any specific or alternativeembodiments, functions, aspects and/or characteristics discussed, areintended to be read in conjunction with the entirety of this disclosure.The hemp and other natural fiber-based insulated panel and temperaturecontrolled shipping system may, however, be embodied in many differentforms and should not be construed as being limited to the embodimentsset forth herein; rather, these embodiments are provided by way ofillustration only and so that this disclosure will be thorough, completeand fully convey understanding to those skilled in the art.

DESCRIPTION BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective exploded view of an exemplary embodiment of a2-panel system whereby each insulating panel covers three sides of theshipping container.

FIG. 2 is a cross-sectional view of an exemplary embodiment of aninsulating panel suitable for various embodiments of the invention.

FIG. 3 is a perspective exploded view of an exemplary embodiment of a3-panel system whereby one insulating panel covers the bottom of theshipping container, one insulating panel covers the top and one longinsulating panel covers the 4 vertical sides of the shipping container.

FIG. 4 is a perspective exploded view of an exemplary 6-panel systemwhereby there is an independent insulating panel for each side of theshipping container.

FIG. 5 a is a perspective exploded view of an exemplary stacked panelsystem whereby 3 insulating panels are stacked on top of each other withthe middle panel having circular cut-outs to hold payload and the topand bottom panels have cut-outs to hold devices (such as phase changematerial) that will help maintain the temperature inside the shippingcontainer.

FIG. 5 b is a see-through perspective exploded view of the stacked panelsystem of FIG. 5 a , wherein 3 insulating panels are stacked on top ofeach other with the middle panel having circular cut-outs to holdpayload and the top and bottom panels have cut-outs to hold devices(such as gel-packs containing phase change material) that will helpmaintain the temperature inside the shipping container.

FIG. 6 is a perspective exploded view of a stacked panel system whereby3 insulating panels are stacked on top of each other with the middlepanel having a rectangular cut-out to hold payload and the top andbottom panels have cut-outs to hold devices (such as gel-packscontaining phase change material) that will help maintain thetemperature inside the shipping container.

FIG. 7 is a perspective exploded view of a wrap-around system wherebyinsulating panels are wrapped on the outside of the shipping containeror assembly of shipping containers.

FIG. 8 is a perspective exploded view of a 3-panel pallet cover systemwhereby one insulating panel covers the bottom of the palletized payloadand two panels cover two opposite sides of the palletized payload withtwo superimposed panels on top of the palletized payload.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

The present invention, as well as features and aspects thereof, isdirected towards providing a hemp and/or other natural fiber-basedinsulated panel or panel system, as well as a temperature controlledshipping and/or short term storage system utilizing one or more of theinsulating panels.

An exemplary embodiment of a device or shipping/storage container mayinclude the following components: one or more properly sized,shape-stable insulating mats or panels made from natural fibers or hempfibers and binders, that may be wholly or partially covered with arecyclable and/or biodegradable, perforated outer film, and assembledinto one or more shapes that fit snugly together when placed into theinterior or onto the exterior of a shipping container or assembly ofseveral shipping containers or a payload. The result is a continuous ornearly continuous insulating layer that reduces the rate of heattransfer between the items in the interior of the container and theenvironment outside the container. The system thus better preserves thequality of temperature-sensitive goods that may be shipped or storedutilizing the device. The combination of the natural fiber or hempinsulating panels and the shipping container create a unique system thatprovides a superior system for transportation of thermally-sensitivegoods. The addition of cold-packs (typically containing a phase changematerial such as frozen water with certain chemical additives, or frozenCO2) into the interior of the shipping container creates a system thatcan maintain a favorable temperature inside the shipping container foran extended period of time. Likewise, heat packs, such as packetscontaining iron, activated carbon and water, may be used to maintain theitems at a warm temperature.

By using hemp and/or other natural fiber-based insulation, this shippingsystem is recyclable, biodegradable, and is more environmentallyfriendly than other shipping systems.

It should further be noted that, due to the moisture absorbingproperties of the natural fiber or hemp insulation being used, and thepresence of perforations in the film covering the natural fiber or hempinsulating panels in whole or in part, the insulating mats reduce theaccumulation of moisture on the inside of the shipping container thatmay otherwise take place if other insulating materials are used. This inturn, leads to better preservation of the quality of the goods inside ofthe shipping container during transportation.

It should also be noted that unlike some other insulating materials, thenatural fiber or hemp fiber insulation helps absorb shocks and vibrationoccurring during transportation. Advantageously, this aspect of thevarious embodiments provides an improved protection of the goods beingtransported.

It should also be noted that should the natural fiber or hemp insulationbecome moist or wet, the insulating properties of natural fiber or hempinsulation degrade much less than other types of bio-based insulation.Advantageously, this can result in better thermal protection of the goodbeing transported.

It should also be noted that because of the semi-ridged structure of thenatural fiber or hemp insulation, stable cut-outs can be made in thehemp insulation which will allow for a customized space in which thegoods being transported can be placed. These specialized cut-outs mayprovide for easier assembly of the goods into the package prior toshipping and also better protection of the goods during transport.Furthermore, the cut-outs from the hemp panels can be readily put backinto the feedstock for manufacture of additional mats with almost zerowasted material.

It should also be noted that the film placed on the outside of thenatural fiber or hemp insulation may include a reflective surface on oneor both sides to enhance the insulating properties of the insulating mator panel.

It should also be noted that the use of a film or covering on theoutside of the natural fiber or hemp insulating mat is not arequirement. The natural fiber or hemp mats or panels without a coveringhave excellent insulating properties.

It should also be noted that the performance of the shipping system maybe further enhanced by placing the temperature sensitive goods alongwith the phase change materials inside a sealable bag before placing thegoods inside the insulated shipping container.

It should also be noted for embodiments that specifically include hemp,that because of the nature of hemp cultivation and hemp fiberprocessing, the hemp insulation requires fewer acres of cultivated landor space than other fibers, such as cotton, to yield a similar amount ofusable insulation (same area of insulation with same insulatingproperties). When compared with the production of other insulationmaterials, for each unit of usable insulation, hemp sequesters more CO2,uses fewer chemicals, uses less water and creates less chemicalpollution. This may also be true for other natural plants for producingnatural fibers.

An exemplary form of performing the creation method associated with thedisclosed device may include the following steps: natural fiber or hempfibers manufactured from sustainably grown plants, mechanicallyprocessed into fibers using little to no chemicals (or an unsubstantialamount of chemicals), with such fibers then combined with a quantity andtype of binder chemical so that the resulting fiber-binder mix iscompostable and recyclable, with that same fiber-binder mix thenprocessed using heat, pressure and other means into a shape-stableinsulating mat. One or more of these insulating mats are then trimmed,optionally covered in whole or in part with a breathable exterior filmand assembled into one or more shapes that fit tightly together whenplaced into the interior or onto the exterior of a shipping container,or assembly of several shipping containers or payload. The result is acontinuous or nearly continuous insulating layer that reduces the rateof heat transfer between the items on the interior of the container andthe environment outside container.

Referring now to figures in which like labels represent like elementsthroughout the several views, further exemplary embodiments, functions,aspects and characteristics of the various embodiments are presented.

FIG. 1 is a perspective exploded view of a 2-panel system whereby eachinsulating panel covers three sides of the shipping container. Theexploded view perspective of a 2-panel system 100 includes twoinsulating panels (120 and 130) whereby each insulating panel coversthree internal sides of the shipping container 110, all insulatingpanels containing natural fibers or hemp fibers as shown in FIG. 2 . Thefirst insulating panel 120 is C-shaped or folded into a C-shape formfrom and unfolded flat form and inserted in the shipping container 110in such a manner that it covers the bottom, one vertical side and thetop of the payload 140 inside the shipping container 110. The secondinsulating panel 130 is also C-shaped or then folded into a C-shape formfrom an unfolded flat form and inserted into the shipping container 110in such a manner that it covers the three remaining sides of the payload140 inside the shipping container 110. The two C-shape insulating panels(120 and 130) are arranged in a way whereby they define an interiorcavity for receiving and housing the payload 140 and, they form acontinuous or nearly continuous layer inside the shipping container 110,thus creating a barrier to heat transfer between the inside and theoutside of the 2-panel system 100. The payload 140 inside the shippingcontainer 110 is thus kept at a more optimum and consistent temperaturewhile within the cavity defined by the 2-panel system, such as duringtransportation or storage. A device or several devices such as phasechange materials (not shown) may be added between the payload 140 andthe interior surfaces of the insulating panels (120 and 130) to maintaina certain temperature range for a certain duration. A Phase ChangeMaterial (PCM) provides advanced thermal protection when shipping orstoring temperature-sensitive products. When PCMs melt and freeze, orchange phases of matter between solid and liquid, they maintain aconstant temperature equal to their melting/freezing point. Aphase-change material suitable for packaging is generally an organic orinorganic substance that acts as a payload’s heating or cooling agent.As the payload’s temperature increases or decreases (depending onseveral factors, from ambient external temperature to the type ofinsulation being used), the PCM works to maintain a stable, consistenttemperature for the duration of its trip or storage.

There are several commonly used phase-change materials within theshipping industry, and each comes with its own benefits and drawbacks.It should be noted that a PCM alone is not effective in maintainingtemperature, as the PCM should be utilized in conjunction with apackaging and insulation system. As a participant in the temperatureregulator for packaging systems, however, it’s important to choose a PCMcarefully. For example, the following considerations should be examinedin selecting a PCM:

If a payload needs to be kept at a particular temperature or temperaturerange, such as at 14° C., with acceptable excursions ranging from 11° C.to 17° C., a PCM should be selected to maintain the temperature withinthat range.

If the payload requires a consistent temperature for a particular periodof time, such as 24 to 48 hours or if the payload has an extendedtravel/storage period, such as 120 hours, a PCM should be selected tothat meets these characteristics.

If the payload vibration or shack sensitive, special packaging solutionsmay be examined to provide sufficient room for and protection of thepayload for the duration of the trip. For example, using dry ice as aPCM may be effective for materials that need to be kept frozen (below-18° C.). However, once the ice sublimates, it results in creating roomfor the payload to move around and possibly become damaged.

Creating contours or cut-outs in the insulating panels canadvantageously alleviate issues that may arise in this scenario.

If the cost of shipment is a concern, a packaging solution or PCM as amore expensive option may not be the best suited for the particularshipping needs. Reusable solutions also may appear more expensive, butbased on cost per use may be more affordable.

If environmental impact is a concern, an appropriate PCM can beselected. For instance, determining what the PCM composed of, and if itis renewable. Further, it should be determined if the PCM is toxic ornon-toxic and if it can be used repeatedly.

There are several types of technology utilized for PCMs. A fewnon-limiting examples include:

Water-based gel packs. Water-based gel packs are among the mostinexpensive forms of PCMs available. However, and gel packs cansometimes provide inconsistent temperature control. Gel packs also mayneed to be conditioned hours before use to avoid thermally shocking thepayload. They are, however, non-toxic, and intact gel packs may be usedseveral times.

Dry ice (frozen CO2). This PCM option is also inexpensive and readilyavailable (but not reusable). Dry ice works well with deep frozenpayloads traveling short distances. Using dry ice as a PCM requirescareful packing to ensure payloads remain safe even as the dry icesublimates. Thus, the use of cut-outs or contours suitable for thepayload may be required.

Vegetable oil-based PCMs. This PCM technology can achieve virtually anytemperature range and maintain it for extended durations of time.Vegetable oil-based PCMs are also biodegradable, non-toxic, andexperience no thermal degradation after many uses.

Petroleum-based PCMs are derived from crude oil. The cost of this PCMtechnology thus fluctuates with the price of crude oil similar to theprice of gasoline. Depending on the petroleum derivative used to createthe PCM, most are toxic and thus, disposal of them may be difficult.

Heavy water (deuterium oxide). This PCM technology is very useful forrefrigerated payloads (such as items that need to be maintained at arange of 2-8° C.). The heavy water PCMs freeze at 3.82° C. While thistechnology is quite effective as a PCM, it must be used with caution,may be difficult to obtain and can be costly.

Eutectic salts. A generic term for many materials that contain a salt insolution at a concentration that yields the lowest freezing point,eutectic salts can vary in safety, price, and effectiveness, based ontheir composition. There may also be disposal or customs issues, basedon the material used.

One or more of the insulating panels may or may not be encapsulated, inwhole or in part, in a plastic film or a film made of other materials,and the film may be perforated or not. In one particular andillustrative, yet non-limiting, embodiment of the 2-panel system 100,the unfolded insulating panel 120 may have a length of approximately 35inches, a width of approximately 12 inches and a thickness ofapproximately 1.5 inches whereas the unfolded insulating panel 130 mayhave a length of approximately 32 inches, a width of approximately 9inches and a thickness of approximately 1.5 inches. Of course, thesemeasurements are merely illustrative and insulating panels of anylength, width and thickness that include the features described hereinare intended to be within the scope of the various embodiments of theinvention and disclosure, which has many different embodiments. In thisand all other embodiments, a material such as an adhesive or a devicesuch as a hook and loop material (e.g., VELCRO) may be used along theedges where the insulating panels meet so as to minimize any gapsbetween the insulating panels. In other embodiments, at locations wherean edge of a first panel rest on the surface of a second panel, a groovecan be formed in the surface of the second panel so that the edge of thefirst panel can rest within the groove creating a tongue-in-grooveconstruction. Further, the adhesive or loop and hook material may alsobe applied to the edge and groove to further secure the panels in place.The payload 140 is shown for illustrative purposes and is not part ofthe 2-panel system.

FIG. 2 is a cross-sectional view of an exemplary embodiment of aninsulating panel suitable for various embodiments of the invention.Referring to FIG. 2 , a cross-sectional view of an exemplary insulatingpanel 200 includes a mat made primarily of natural or hemp fibers 230and a film 210 in which the insulating panel 200 may be wholly orpartially encapsulated. In the illustrated embodiment, the encapsulatingfilm 210 includes an array of micro-perforations or apertures 220 on oneside that faces the payload 140 once inserted in the shipping container110. In some implementations, the micro-perforations 220 are present onthe entire film 210 while in other embodiments, the micro-perforations220 are present on portions of the panel that are adjacent to and/orproximate to the payload 140. In various embodiments, the encapsulatingfilm 210 may be constructed of plastic, bio-plastic, paper or othermaterials. In some implementations, the film 210 may also include areflective surface on one or both sides to enhance the insulatingproperties of the insulating panel 200. In some implementations, theinsulating panel 200 is not encapsulated with an encapsulating film 210.In some embodiments, the film may be a stand-alone material that isapplied to the hemp fibers 230, or a sheath that is slid over the hempfibers 230 or even a material that is sprayed onto the hemp fibers andthen perforated after application. In some embodiments, the film may benaturally porous or configured such that moister or air may pass throughthe surface, while in other embodiments the film may be water and/or airtight. In some embodiments, super-absorbent beads may be includedbetween the film 210 and the natural or hemp fibers 230 for furtherfacilitate the collection of moister. In other embodiments, the film 210may include pockets for housing super-absorbent beads or material suchthat the pockets can be removed for proper disposal while the remainderof the material can be recycled.

FIG. 3 is a perspective exploded view of an exemplary embodiment of a3-panel system whereby one insulating panel covers the bottom of theshipping container, one insulating panel covers the top and one longinsulating panel covers the 4 vertical sides of the shipping container.Referring now to FIG. 3 , the illustrated 3-panel system 300 inaccordance with an exemplary embodiment of the invention is shown asincluding three insulating panels (310 and 320) and a shipping container110. In the illustrated embodiment, the combination of the three panelscover all internal walls of the shipping container 110. The insulatingpanels may be primarily constructed of natural fibers or hemp fibers asshown on FIG. 2 . In the illustrated embodiment, one insulating panel310 covers the bottom of the shipping container 110, one insulatingpanel 310 covers the top of the shipping container 110 and one longinsulating panel 320 covers the 4 vertical internal walls of theshipping container 110. To assemble the 3-panel system 300, theinsulating panel 310 is inserted flat at the bottom of the shippingcontainer 110. The insulating panel 320 is then inserted inside theshipping container 110 and folded in a way that it covers the fourinternal vertical sides of the shipping container 110 with each fold orthe meeting junction of the edges of the long insulating panel 320 beinginserted into the corners of the shipping container 110. It should alsobe appreciated that the insulating panel 320 may be constructed as a boxwithout a top or bottom and then slid into the shipping container orover the payload. The insulating panel 310 is added on top of theinsulating panel 320 to form a continuous or nearly continuousinsulating layer inside the shipping container 110 which surrounds thepayload 140 being transported. A device or several devices (such asgel-packs containing phase change materials) may be added between thepayload 140 and the insulating panels (310 and 320). The payload 140 isshown for illustrative purposes and is not part of the 3-panel system.

FIG. 4 is a perspective exploded view of an exemplary 6-panel systemwhereby there is an independent insulating panel for each side of theshipping container. Referring now to FIG. 4 , the exemplary 6-panelsystem 400 includes 6 insulating panels (3 styles 410, 411, 412) and ashipping container 110 whereby there is an independent insulating panelfor each internal side of the shipping container 110. All insulatingpanels are primarily made of natural fibers or hemp fibers such as shownon FIG. 2 . To assemble the 6-panel system 400, one of the insulatingpanels 410 is inserted flat at the bottom of the shipping container 110.The insulating panels 411 are then inserted inside the shippingcontainer 110 and laid against two opposite vertical walls of theshipping container 110. The insulating panels 412 are then inserted inthe shipping container 110 and laid against the two remaining oppositewalls, orthogonally to the insulating panels 411, of the shippingcontainer 110. The remaining insulating panel 410 is added on top of thevertical insulated walls 411 and 412 to form a continuous or nearlycontinuous insulating layer inside the shipping container 110 whichsurrounds the payload 140 being transported. A device or several devicessuch as phase change materials may be added between the payload 140 andthe insulating panels (410, 411, 412). The payload 140 is shown forillustrative purposes and is not part of the 6-panel system.

FIG. 5 a is a perspective exploded view of an exemplary stacked panelsystem whereby 3 insulating panels are stacked on top of each other withthe middle panel having circular cut-outs to hold payload and the topand bottom panels have cut-outs to hold devices (such as phase changematerial) that will help maintain the temperature inside the shippingcontainer. Referring now to FIG. 5 a , the exemplary stacked panelsystem 500 is shown as including 3 insulating panels stacked verticallyon top of each other and a shipping container 110. As illustrated, themiddle panel 520 includes multiple cut-outs 530 that can be made ofdiffering sizes and shapes to hold payload. In the illustratedembodiment, the cut-outs are shown as being circular or cylindrical as anon-limiting example. The top and bottom panels 510 have cut-outs tohold phase change materials. All insulating panels are primarily made ofnatural fibers or hemp fibers such as shown on FIG. 2 . To assemble theexemplary stacked panel system 500, the insulating panel 510 is insertedflat at the bottom of the shipping container 110. The insulating panel520 is then inserted flat on top of the insulating panel 510. A thirdinsulating panel 510 is inserted flat on top of the stack. The cut-outs540 in the insulating panels 510 are designed to hold a device orseveral devices such as phase change materials. The cut-outs 530 in theinsulating panel 520 are designed to hold a payload. As shown on FIG. 5b , the cut-outs 530 in the middle panel 520 are cut all the way throughthe insulating panel. In some implementations, the cut-outs may not passall the way through the insulating panel 520 and as such, a bottomsurface within the cut-outs can provide support for the payload.

FIG. 5 b is a see-through perspective exploded view of the stacked panelsystem of FIG. 5 a , wherein 3 insulating panels are stacked on top ofeach other with the middle panel having circular cut-outs to holdpayload and the top and bottom panels have cut-outs to hold devices(such as gel-packs containing phase change material) that will helpmaintain the temperature inside the shipping container. As shown on FIG.5 b , the cut-outs 540 are not cut all the way through the insulatingpanels 510. In this particular embodiment, the insulating panels are notencapsulated in a film. Other implementations may include insulatingpanels encapsulated, either in whole or in part in a film as previouslydescribed. Other implementations may have a different number ofinsulating panels not necessarily arranged in a vertical stack.Insulating panels may be placed side-by-side or in other arrangements.Other implementations may have cut-outs in only one panel or cut-outs inseveral panels. Cut-outs to a device or several devices (such asgel-packs containing phase change materials) may be placed on the sidesof the panel holding the payload in addition or instead of being on topand/or at the bottom of the payload panel.

FIG. 6 is a perspective exploded view of a stacked panel system whereby3 insulating panels are stacked on top of each other with the middlepanel having a rectangular cut-out to hold payload and the top andbottom panels have cut-outs to hold devices (such as gel-packscontaining phase change material) that will help maintain thetemperature inside the shipping container. Referring to FIG. 6 , theexemplary stacked panel system 600 includes 3 insulating panels stackedon top of each other and a shipping container 110, whereby the middlepanel 610 has a rectangular cut-out 620 to hold payload and the top andbottom panels 510 have cut-outs to hold one or more devices such asphase change materials that will help maintain a desired temperaturerange for a prolonged period of time, such as during transportation orstorage. All insulating panels are primarily made of hemp fibers such asshown on FIG. 2 . The stacked panel system 600 is assembled the same wayas the stacked panel system 500. The middle panel 610 has a rectangularcut-out 620 all the way through the insulating panel 610. Otherimplementations may have a cut-out that does not pass all the waythrough the insulating panel 610. Similar to the stacked panel 500, someembodiments may present a different number of insulating panels andpanel arrangements with or without cut-outs.

FIG. 7 is a perspective exploded view of a wrap-around system wherebyinsulating panels are wrapped on the outside of the shipping containeror assembly of shipping containers. Referring now to FIG. 7 , theexemplary wrap-around system 700 is illustrated as including 6insulating panels that cover the outside of an assembly of shippingcontainers or assembly of goods 740, such as a palletized load of boxes.All insulating panels are primarily made of hemp fibers such as shown onFIG. 2 . Thus, this embodiment includes two side panels 710, two endpanels 720 and a top and bottom panel 730. It should be appreciated thatin some embodiments, each of the panels may be identically dimensioned(i.e. for a cubical load) or one or more of the panels may havedifferent dimensions from one or more of the other panels. For assembly,the bottom panel 730 can be placed on a surface and the payload 740 canbe stacked on top of the bottom panel 730. Once the load is in place,the side panels 710 and end panels 720 can be placed into position andfinally, the top panel 730 can be placed on top of the payload 740. Insome embodiments, the panels can be secured to the payload 740 by acellophane wrapping, shipping tape, adhesive on the inside surface ofthe panels, straps, metal strips, clamps, a sheath, hook and nookfasteners or tape as non-limiting examples. The payload can be coveredin a material, such as paper or plastic wrap and the panels can beattached thereto. Further, as illustrated in other embodiments, one ormore of the panels 710, 720 and 730 may include recessed areas orcut-outs for receiving and containing devices such as phase changematerials that will help maintain a desired temperature range for aprolonged period of time, such as during transportation or storage.

FIG. 8 is a perspective exploded view of a 3-panel pallet cover systemwhereby one insulating panel covers the bottom of the palletized payloadand two panels cover two opposite sides of the palletized payload withtwo superimposed panels on top of the palletized payload. Referring nowto FIG. 8 , an exemplary 3-panel cover system 800 for a large shippingcontainer, assembly of multiple shipping containers or assembly of goodsin accordance is illustrated. For simplicity, this embodiment isreferred to herein as a “pallet cover system,” although a pallet neednot be used as part of this system or in its various embodiments. Forsimplicity, the payload illustrated as being covered in the illustratedembodiment of the pallet cover system is referred to herein as a“shipping container,” although the payload may be a single largeshipping container, an assembly of shipping containers, or an assemblyof goods. As shown, the 3-panel pallet cover system includes oneinsulating panel 810 laying on a pallet 750, a second insulating panel820 covering the top of the shipping container 740 and also covering twoopposite sides of the shipping container 740, and a third insulatingpanel 830 covering the top of the first insulating panel 820 and the tworemaining exposed sides of the shipping container 740. All insulatingpanels are primarily made of hemp fibers such as shown on FIG. 2 . Insome embodiments, the insulating panel 820 and the insulating panel 830are rigidly formed in a C shape or U shape. In other embodiments theinsulating panel 820 and 830 may be hinged using any of a wide varietyof techniques, such a scoring, creasing, using an actual hinge, using athinner portion of material, using interlocking pieces, using tongue andgroove joints, bendable or otherwise foldable along lines 822 a and 822b for insulating panel 820 and 832 a and 832 b for insulating panel 830.Advantageously, the embodiments that can be folded are also suitable forflat-pack shipping and thus more cost effective for shipping to variouslocations. As such, the foldable panels can be packaged and shipped in acost effective manner and then the panels can be folded so that theyadapt to the shape of the shipping container 740. In some embodiments,the panels can be secured to the payload 740 by a cellophane wrapping,shipping tape, adhesive on the inside surface of the panels, straps,metal strips, clamps, a sheath, hook and nook fasteners or tape asnon-limiting examples. The payload can be covered in a material, such aspaper or plastic wrap and the panels can be attached thereto. Theinsulating panels may be encapsulated in a film made of materials suchas but not limited to plastic, bioplastics and paper. The surface of thefilm may have reflective properties. In one particular and illustrative,yet non limiting, embodiment of the 3-panel pallet cover system 800, theinsulating panel 810 may have a length of approximately 48 inches, awidth of approximately 40 inches and a thickness of approximately 1inch, the insulating panel 820 may have a length of approximately 136inches, a width of approximately 40 inches and a thickness ofapproximately 1 inch and the insulating panel 830 may have a length ofapproximately 140 inches, a width of approximately 52 inches and athickness of approximately 1 inch. Of course, these measurements aremerely illustrative and insulating panels of any length, width andthickness that include the features described herein are intended to bewithin this disclosure and make up the overall invention, which has manydifferent embodiments.

As previously described, the insulating panels may be held together orjoined in a variety of manners. The use of adhesive or hook and loop(VELCRO) materials have been described. In addition, the use of tongueand groove type connections have been described as being molded, carvedor cut into the panels to create a connection. Further, the use of tabsand spaces can be utilized such that the tabs of a panel align with thespaces of another panel, and vice versa, thereby creating a connection.Other techniques may also be used including bio-degradable tape,fasteners, pins, etc.

In some embodiments, the container may be constructed to include pocketson the interior or exterior. These pockets can also be used to receiveand securely hold the insulating panels in place. It should also beappreciated that in some embodiments, the insulating panels, whenassembled and secured, can operate as the shipping container as well. Insuch embodiments a water resistant film can be applied to the exteriorof the insulating panels to further protect the contents.

While the various embodiments have been described as predominantlyrectangular cubes in shape, it should be appreciated that the presentinvention could be applied in any shape, including spherical, orbed,pyramidal, tubular, etc. The various panels may be created in a mold,extruded or carved from larger sections of material.

Different features, variations and multiple different embodiments havebeen shown and described with various details. What has been describedin this application at times in terms of specific embodiments is donefor illustrative purposes only and without the intent to limit orsuggest that what has been conceived is only one particular embodimentor specific embodiments. It is to be understood that this disclosure isnot limited to any single specific embodiments or enumerated variations.Many modifications, variations and other embodiments will come to mindof those skilled in the art, and which are intended to be and are infact covered by this disclosure. It is indeed intended that the scope ofthis disclosure should be determined by a proper legal interpretationand construction of the disclosure, including equivalents, as understoodby those of skill in the art relying upon the complete disclosurepresent at the time of filing.

In the description and claims of the present application, each of theverbs, “comprise”, “include” and “have”, and conjugates thereof, areused to indicate that the object or objects of the verb are notnecessarily a complete listing of members, components, elements, orparts of the subject or subjects of the verb.

The present invention has been described using detailed descriptions ofembodiments thereof that are provided by way of example and are notintended to limit the scope of the invention. The described embodimentscomprise different features, not all of which are required in allembodiments of the invention. Some embodiments of the present inventionutilize only some of the features or possible combinations of thefeatures. Variations of embodiments of the present invention that aredescribed and embodiments of the present invention comprising differentcombinations of features noted in the described embodiments will occurto persons of the art.

It will be appreciated by persons skilled in the art that the presentinvention is not limited by what has been particularly shown anddescribed herein above. Rather the scope of the invention is defined bythe claims that follow.

1. A system for maintaining temperature during shipment and/or storage, the system comprising: a container comprising a top, a bottom, and a plurality of sides, wherein each of the top, bottom, and plurality of sides of the container comprises an interior surface which collectively define an interior of the container; a payload disposed in the interior of the container; a phase change material disposed in the interior of the container; a plurality of flexible insulating panels located in the interior of the container, wherein each flexible insulating panel is comprised of an insulating composition comprising natural fiber and a binder wherein each flexible insulating panel comprises an interior surface facing the payload and the phase change material and an exterior surface facing the interior surface of the top, bottom or plurality of sides of the container, wherein the plurality of flexible insulating panels collectively extend about the interior surfaces of the top, bottom, and plurality of sides of the container, wherein the plurality of flexible insulating panels collectively are located between the payload and the interior surfaces of the top, bottom, and plurality of sides of the container, and further wherein the plurality of flexible insulating panels collectively are located between the phase change material and the interior surfaces of the top, bottom, and plurality of sides of the container.
 2. The system of claim 1 wherein the natural fiber in each flexible insulating panel comprises hemp fiber.
 3. The system of claim 2 wherein each flexible insulating panel is the form of a compressed mat comprising hemp fiber bound together by the binder.
 4. The system of claim 3 wherein each compressed mat is formed by heating a mixture of the hemp fiber and the binder, and then compressing the heated mixture to form the mat.
 5. The system of claim 3 wherein each compressed mat is shape-stable and configured to bend at least 90 degrees without breaking.
 6. The system of claim 2 wherein the flexible insulating panels comprise substantially more hemp fiber than binder by volume.
 7. The system of claim 6 wherein the flexible insulating panels comprise at least 40% hemp fiber by volume.
 8. The system of claim 2 wherein the insulating composition consists essentially of hemp fiber and binder.
 9. The system of claim 2 wherein the binder comprises polylactic acid.
 10. The system of claim 2 wherein each of the flexible insulating panels is rectangular in shape, wherein the interior surfaces of the flexible insulating panels collectively define a rectangular cavity, and further wherein the payload and the phase change material are located in the rectangular cavity.
 11. The system of claim 10 wherein each of the flexible insulating panels has a flat interior surface, a flat exterior surface and a thickness of from about 0.5 to about 2 inches.
 12. The system of claim 11 wherein at least one of the flexible insulating panels extends along a top of the payload, at least one of the flexible insulating panel extends along a bottom of the payload, and further wherein at least four of the flexible insulating panels extend about one or more sides of the payload.
 13. The system of claim 12 wherein the container is comprised of cardboard.
 14. The system of claim 13 wherein the container is rectangular in shape.
 15. The system of claim 14 wherein the flexible insulating panels comprise a first mat folded in a c-shaped manner and extending around the interior surfaces of the top, bottom and one side of the container, and a second mat folded in a c-shaped manner extending around the interior surfaces of three sides of the container.
 16. The system of claim 10 wherein at least one of the flexible insulating panels is attached to at least one other flexible insulating panel.
 17. The system of claim 10 wherein the plurality of flexible insulating panels collectively line the interior surfaces of the top, bottom, and plurality of sides of the container.
 18. The system of claim 2 wherein each flexible insulating panel is configured to absorb moisture.
 19. The system of claim 2 wherein each insulating panel comprises a film encapsulating the insulating composition.
 20. The system of claim 19 wherein, for each flexible insulating panel, the film comprises a plurality of perforations extending along at least one side of the respective flexible insulating panel.
 21. The system of claim 20 wherein the film is comprised of plastic.
 22. The system of claim 20 wherein the film is comprised of kraft paper.
 23. The system of claim 1 wherein the phase change material comprises a plurality of gel packs.
 24. The system of claim 1 wherein the phase change material is located between the payload and the interior surfaces of the flexible insulating panels.
 25. The system of claim 1 wherein each flexible insulating panel is in the form of a shape-stable mat configured to bend at least 90 degrees without breaking.
 26. A system for maintaining temperature during shipment and/or storage, the system comprising: a rectangular cardboard box comprising a top, a bottom, and four sides, each of the top, bottom, and four sides comprising an interior surface that collectively define an interior of the box; a payload disposed in the interior of the box; a phase change material disposed in the interior of the box; a plurality of flexible, rectangular insulating panels located in the interior of the box, the plurality of flexible, rectangular insulating panels comprising: i) a top flexible, rectangular insulating panel extending about a top of the payload and the box top and comprising a bottom surface facing the payload and a top surface facing the box top, ii) a bottom flexible, rectangular insulating panel extending about a bottom of the payload and the box bottom and comprising a bottom surface facing the box bottom and a top surface facing the payload, and iii) four flexible, rectangular insulating side panels collectively extending about one or more sides of the payload and the four sides of the box, each of the four flexible, rectangular insulating side panels comprising an interior surface facing the payload and an exterior surface facing a side of the box, wherein each flexible insulating panel is comprised of an insulating composition comprising natural fiber and a binder, wherein the interior surfaces of the flexible, rectangular insulating panels collectively define a rectangular cavity, and further wherein the payload and the phase change material are located in the rectangular cavity.
 27. The system of claim 26 wherein the natural fiber comprises hemp fiber.
 28. The system of claim 27 wherein each flexible insulating panel is the form of a compressed mat comprising hemp fiber bound together by the binder.
 29. The system of claim 28 wherein each compressed mat is formed by heating a mixture of the hemp fiber and the binder, and then compressing the heated mixture to form the mat.
 30. The system of claim 28 wherein each compressed mat is shape-stable and configured to bend at least 90 degrees without breaking.
 31. The system of claim 27 wherein the flexible insulating panels comprise substantially more hemp fiber than binder by volume.
 32. The system of claim 27 wherein the flexible insulating panels comprise at least 40% hemp fiber by volume.
 33. The system of claim 27 wherein the insulating composition consists essentially of hemp fiber and binder.
 34. The system of claim 27 wherein the binder comprises polylactic acid.
 35. The system of claim 26 wherein the top flexible, rectangular insulating panel lines the box top, wherein the bottom flexible, rectangular insulating panel lines the box bottom and further wherein the four flexible, rectangular side insulating panels collectively line the box sides.
 36. The system of claim 26 wherein each of the four flexible, rectangular insulating panels has a flat interior surface, a flat exterior surface and a thickness of from about 0.5 to about 2 inches. 